Build Your Own Solar Panel
by Phillip Hurley
TABLE OF CONTENTS
Table of contents
Introduction
Solar cells
Solar cell basics
Amorphous cells
Flexible solar cells
Crystalline solar cells
Monocrystalline and polycrystalline cells
New cells vs. old-style cells
Solar cell output
Watt rating of solar cells
Testing solar cells
Match solar cell output
Tools for testing solar cells
Using a calibrated cell
Solar panels
Solar panel output for different applications
Solar panel ratings
Designer watts
Finding and choosing cells for solar panels
Tab and bus ribbon
Panel frames
Thermal resistance
Moisture resistance
Table of contents
Solar panels, continued
UV resistance
Glass in solar panels
Plexiglas in solar panels
Solar panel backing and sides
The benefits of long screws
Planning the panel wiring - series and parallel connections
Voltage and distance to the battery
Panel arrays and connections
Panel size and shape
Connecting solar cells
Choose and inspect the cells carefully
Preparing the tab ribbon
Flux
Soldering
Soldering tips
Soldering technique
Types of solder
Building a solar panel
Materials and tools
Figuring panel output
Calculate the number of cells you will need
Plan the panel layout
Table of contents
Building a solar panel, continued
Over-all panel length
Over-all panel width
Bar stock length
Cut the tab ribbon
Prepare the tab ribbon
Tinning
Crimp the tab ribbon
Attach the tab ribbon to the cells
Pre-tabbed cells
Make a layout template
Solder the cells together
Prepare the panel structure
Attach the screen
Place the cells on the panel
Attach the tab ribbons to the bus ribbons
Insulate the bus connectors
Junction box
Test the panel
Seal the panel
A small solar panel array project
Solar II project specifications
Panel layout and dimensions
Table of contents
Panel construction details
Panel backing
Cutting the Plexiglas
Drilling the Plexiglas
Drill Plexiglas, backing and sidebars together
Output holes
Attach sidebars to backing
Attach screen to backing
Junction box
Tab and bus ribbon
Coating interior panel parts
Cell preparation
Tab ribbon length
Soldering tab ribbon to the cells
Cell layout template boards
String construction
Plexiglas cover
Panel clips
Purchasing and working with solar cells
Off-spec or cosmetically blemished solar cells
Repairing solar cells
Creating cell fingers
Using broken solar cells
Table of contents
Making tab and bus ribbon
Tinning the cut foil
Other options for connecting cells
Encapsulants
De-aerate the silicone
Cutting the silicone
Solar electric system
Charge controllers
Cables and connectors
Batteries
Mounting panels
Solar panel location
Orientation
Panel maintenance
Appendix
Tools and materials
Suppliers
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